A milestone in maintenance: Products detect a need for maintenance

The smart products from the isense range include a sensor for continuous measurement of push and pull forces (EC. P – Push/pull detection) as well as a sensor to detect chain link breakage (EC.B – Break detection). The service life of moving chainflex® cables can be predicted exactly until the warranty period expires. For the period thereafter, a sensor called CF.Q (Cable Fracture/Quality) has been developed. The remaining service life is estimated by monitoring the electrical parameters.

For condition measurements, such as acceleration or temperatures, the EC.M (Motion) can be used, the measured values are the basis for further more complex calculations. The PRT.W (Wear) sensor provides wear status of the slewing ring bearings . For all linear drives, the DL.W (Wear) sensor provides timely wear status. This data is only a small part of what makes the isense product family a strong and smart tool for the 'Industry 4.0'. These sensors only become useful when linked to the icom module, a data collection module that imports the measured values of the isense product family into the system.

To view this video please enable JavaScript, and consider upgrading to a web browser that supports HTML5 video

Richard Habering presents the new developments in smart plastics during Hannover Messe (HMI)

The sensors at a glance:

iCOM: the data concentrator

The following sensors become especially effective due to their linkage with the icom module.

A data concentrator – that can transfer the measured values to a system of the isense product family. How the sensor data can be further processed depends on the respective system chosen. igus® currently offers four variants.

EC.M: e-chains® movement & EC.W: e-chains® abrasion

Always in motion: EC.M sensor makes this possible

To record the data the EC.M sensor is installed on the moving end of the energy chain. It detects values such as acceleration, speed, temperature and completed cycles, and, from them, determines the distances completed as well as the remaining service life of the system. Wear detection with the EC.W sensorAn abrasion sensor measures the wear, depending on the product, at the crossbar, at the pin/bore connection or at the liners and sends a signal when the limit is reached.

EC.I: Integrated

Non-contact wear measurement

For roller chains, e.g. series P4, the pin/bore connection is the mechanically most stressed component. Integrated directly in the chain link, the EC.I sensor measures the percentage wear of the pin/bore connection without contact and in this way enables the timely planning of replacement or repair.

EC.P: Push/pull detection

The forces are critical: EC.P sensor measures push/pull

Use of the EC.P sensor saves maintenance personnel from having to travel many kilometres - thanks to its status information always being available and which can automatically be passed on to the isense system. The principle has been successfully used as the so-called push/pull detector system by igus® for 14 years.

EC.B: e-chains® breakage

Chain breakage as an easily solvable problem

The EC.B break detection sensor from igus® reduces the amount of work of maintenance technicians tasked with looking after crane installations and gantries. This applies from classical smaller indoor cranes in production facilities right up to the huge cranes used in ship-building. The EC.B sensor can detect breakage of a chain link caused by parts falling into the system or similar. In the past, this problem was often a critical factor in the failure of a crane as breakage of a chain link automatically leads to overloading and failure of the opposite side.

CF.Q: chainflex® quality

Hidden cable damage detected by CF.Q sensor at an early stage

The CF.Q sensor indicates changes in the electrical properties; and allows detection of impending cable failure in advance. The electrician then decides what priority the replacement of a cable has and what the consequences of a defect might be.

CF.P: Push/pull detection

Easy life for the cables

Tensile forces acting on the cables of an e-chain system® can significantly reduce the service life! The CF.P system measures the forces directly at the strain relief and indicates the need for action in a timely manner.

EC.RC: Run Control

Monitoring the operating status of the e-chains®, especially in guide troughs on long travels.

Sensors measure and check the position of the energy chain. In this way, the machine is prevented from continuing to operate when mechanical faults occur; meaning that total loss of the chain or an electrical shutdown due to cable damage are a thing of the past.

DLT.W: wear measurement

Used to detect when the wear limit of a drylin® linear unit

has reached a level normally associated with the end of the guide‘s service life. A plastic element that has an integrated sensor and can be retrofitted, signals the need for replacement in good time.

PRT.W: Wear measurement

To determine the wear limit of iglidur® slewing ring bearings. Mounted in a milled slot below the sliding elements

Mounted in a milled slot below the sliding elements of the PRT, the PRT.W sensor measures the wear and tear and can indicate the required replacement promptly via the icom communication module before a cable failure.

isense stand-alone

Machinery can be switched off in two ways: directly by means of the NC contact or through evaluation via an I/O interface of the customer's PLC

Customers can arrange for the data to be sent to them via a serial interface (RS2322/UART) so that they can evaluate the data themselves.

isense offline

Keep track of things at all times in large halls

An additional industrial PC is needed to display the messages via the customer's intranet.

No connection to the Internet and therefore no comparison of the maintenance recommendations with an online database

Manual update of service life information through comparison with the igus® database necessary. Good overview on the IPC: All impending failures in the production environment are displayed

Ideal for production managers and shift supervisors who are interested in facilitating their everyday work in component manufacturing or service provision and want to deploy their maintenance technicians efficiently.

isense online

Use the best method to plan servicing work and only do the work that is really necessary

Efficient work prioritising after the sensor warning, and thanks to integration into the ERP, appropriate replacement parts from stock.

Predictive and plannable servicing work due to early information on required maintenance or replacement

Data from the igus® laboratory are processed on a server with the anonymised customer data and also with open data of other customer applications in order to produce a data model

Service life forecasts from the protected customer area are regularly compared with the data model

Benefits from millions of test data in the igus® database and learns something new every day

Application examples of our customers

smart plastics in use at an Austrian automotive supplier

This factory in Steyr is the biggest and most important engine factory of a car manufacturer. On average, an engine comes off the assembly line every 14 seconds - in peak periods, more than 6,000 engines are produced every working day. This output can only be achieved with a high degree of automation with reliable components. This is why companies rely on smart plastics from igus® in order to avoid unforeseen failures and machine shutdowns.

Tested! In the industry's largest test lab

Anyone who is able to make reliable and useful predictions around maintenance work is one step ahead of the competition. In the age of digitalisation, more than big data is required for such predictions. In order to be able to use the sensor data to derive the correct recommendations for work to be accurately scheduled, long term empirical values from the igus® test database are used. The service life of all igus® products can be calculated online and quickly delivered. To this end, igus® operates the largest test labs in its industry. The heart of igus® innovation beats there.

Day to day maintenance recommendation

Online status monitoring from anywhere in the world - day to day maintenance recommendation

In addition to the maintenance recommendation time in days, all measured sensor values can be displayed with history on a detailed page. In this way, exceptional operating conditions or creeping mechanical changes can be detected early on and corresponding measures initiated at an early stage.

Yes, I would like to receive information on current products and services of igus® by e-mail. I agree to the exclusive use of my data by igus® in the framework of advertising messages in accordance with the data protection regulations. I am aware that I can withdraw my consent prospectively at any time by means of the "Unsubscribe" link contained in every e-mail.

Cookies are important for a website to function correctly. In order to provide you with a more enjoyable website experience we use cookies to store your information. This allows us to provide you with a secure login, to collect statistical information for enhanced website functionality and to provide you with content that is tailored to your needs. Click on „Privacy Policy“ for a detailed description of the types of cookies we use and for information on opt-out options.